PerTronix JBA Exhaust 1823S - Manual (Page 3)

7. On the Passenger Side remove the dipstick. The dipstick bolts to the head on the topside and press-fits into the oil pan
on the bottom side. Unbolt the dipstick bracket and gently wiggle the dipstick tube upward out of the pan. Remove the
flexible hot air tube attached to the heat riser tube. Unbolt the heat riser tube. Unbolt the manifold from the head and
remove.
8. Remove the gaskets and any gasket material or any carbon deposits that remain on the head surface. The use of a gasket
removal agent or scraper will ease the removal of any gasket material. Use care not to get debris into ports or spark plug
holes.
9.Test fit the passenger side header. On some models, the heat shield under the passenger floor pan comes close to the
collector flange. If necessary, clearance the heat shield slightly.
10. Using the gasket and hardware supplied, bolt both headers to the head. Torque the fasteners to factory specifications.
(30-35 ft. Lbs.)
11. Install the EGR tube at the back of the header. On CA models with A.I.R. reinstall the Air Injection tubes.
12. Re-install the heat riser tube so that the tube is allowed to draw hot air from around the header.
13. On vehicles equipped with factory spark plug wires, 4 spark plug boots and terminals must be changed using the
supplied parts. On the driver’s side, the 3 forward boots must be changed. On the passenger, the second boot back must be
changed.
14. Reinstall the plug wires. Reinstall the dipstick tube.
15. Check the clearance of all battery cables and wiring looms to insure that they are not too close to the headers.
16. JBA down pipes are required to complete the exhaust installation, part #1821SY / 1822SY sold separately. Refer
to the illustration below. Temporarily install down pipes on headers, carefully measure the distance from the rear con-
verter flange (ahead of muffler) to the end of the passenger side down pipe. Add 2 inches to this measurement. Now cut
the converter pipe ahead of the catalytic converter using the measurement taken (+2”). On the passenger side measure
approximately 4 1/2 inches from bend and make cut. Install the converter assembly by sliding the expanded pipes over
the down tubes. Check for clearance on everything. If clearance is good weld the pipes into place using MIG process.
(Converter pipes are stainless steel, oxyacetylene welding is NOT recommended!) Install the converter assembly using the
supplied hardware and gaskets. Reconnect all 4 O2 sensor plugs.
17. Check to make sure that all the wiring, fuel lines, transmission cooler lines, brake lines, hoses, etc. are clear of the
headers or any exhaust components and reroute or relocate those components as necessary.
18. Reconnect the negative battery cables.
19. Start the engine and let it warm up, test drive. Check for leaks.
Shut engine off and let it cool down. Check to make sure all fasteners
are tight.
20. Periodically check and retighten the header bolts.